bravo ii sterndrive manual

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bravo ii sterndrive manual

Depression, ADHD, memory loss, agitation: These may seem like inevitable byproducts of modern lives spent multitasking, not getting enough sleep, and operating on digital overload. But while much of the brain’s work still remains a mystery, a growing body of scientific evidence suggests that the food you eat directly affects how well your brain functions. Brain health also pl.The guests range from super celebs (Jamie Foxx, Arnold Schwarzenegger, etc.) and athletes (icons of powerlifting, gymnastics, surfing, etc.) to legendary Special Operations commanders and black-market biochemists. For most of my guests, it’s the first time they. Superior quality and workmanship. Controls you can always count on. Traditional to advanced digital platforms. Each built the only way we know how. For the best experience, consider updating your web browser.Quick planing. Improved fuel economy. Everything you need to get going - and get going fast. For twin applications up to 55 mph, gas engines up to 450hp and diesel engines up to 370hp. Mercury has made it easy for you to purchase a printed copy or to download and print your own copy. To order a printed version of the Service Manual for your particular Mercury Outboard or MerCruiser Engine, click here. Please have your outboard or sterndrive serial number before placing the order. Mercury Marine is a division of Brunswick Corporation. For further information on how we use cookies and how to change your browser settings, please read our Cookie Policy. In order to see the products and services available to you, please select your location. Drive Shaft Housing Numbers on the heads of the met- ric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Sections and parts are listed at front of this manual. Page Numbering Two number groups appear at the bottom of each page.

If NSS (not sold separately) sometimes GM part number will be given in description column. QTY.: The quantity that must be ordered. It provides specific information, including procedures for disassembly, inspection, assembly and adjustment, to enable dealers and service mechanics to repair these products. During the next 5 hours, operate at intermittent full throttle. In consideration of these factors, Mercury MerCruiser has adjusted some maintenance intervals and corresponding tasks to be performed. In some cases, this may allow for more tasks to be performed in a single visit to the servicing dealer, rather than multiple visits. Lubricate U-joints splines. Lubricate gimbal bearing and engine coupler. Check continuity circuit for loose or damaged connec- tions. Test MerCathodeR unit output on Bravo Models. Retorque engine mounts. Check spark plugs, wires, distributor cap and ignition timing. Check and adjust idle speed. Fluid Capacities NOTICE Unit Of Measurement: U.S. Quarts (Liters) All capacities are approximate fluid measures. Model Bravo One Bravo Two Bravo Three Sterndrive Unit Oil Capacity 88 (2603) 104 (3076) If cable is lubricated while extended, hydraulic lock of cable could occur. CAUTION If more than 2 fl. oz. (59 ml) of oil is required to fill sterndrive unit, an oil leak may exist. If water runs out sterndrive unit is leaking and must be resealed. Follow instructions on can for proper application. Entire power package should be cleaned and external surfaces that have become bare should be repainted with Quicksilver Primer and Spray Paint at recommended intervals. Refer to SECTION 1B. U-joint bellows may develop a “set” if unit is stored in raised position and may fail when unit is returned to ser- vice. Referrals to specific sections of this manual are made where special tests or repair procedure are to be performed.

Because of the relationship between Power Package components (engine and sterndrive), it will be necessary in some cases to simultaneously refer to the appropriate Engine Service Manual for further troubleshooting information. Properly reassemble control box. Install Propeller incorrectly installed.Inspect and replace if necessary. Rotate shaft back and forth.This could affect engine to transom Repair boat as necessary. Squirt oil on fitting and hose connections and on the shift Vacuum leaks.If oil is sucked in at any point, a vacuum leak exists. Properly adjust drive unit trim angle. Damaged propeller. Repair or replace. Water test boat using a lower pitch Improper propeller pitch. propeller. Properly adjust drive unit trim angle. Redistribute boat load to stern. If bow overweight is caused by permanently Boat is bow heavy.Replace cable. (Refer to SECTION 2) Steering cable too short (sharp bends) Select and install proper length cable.The following is offered as a guide only and neither Mercury MerCruiser nor the helm manufacturer are responsible for any consequences resulting from incorrect repairs. If no voltage is connections. Check for battery voltage at terminal Faulty solenoid. Connect a continuity meter between leads and 17. Check for cause of low oil level and Oil level low. correct. Add oil to pump and bleed system. Replace pick-up screens. Trim Pump Runs Slowly In Both Directions Cause Special Instructions Check the condition of the oil It may be. Mode switch wiring harness connector Secure connection 47.If no voltage is indicated, replace switch. Check leads for loose or Open circuit in wiring harness. Faulty control module. Replace. Check voltage at terminal 44. READINGS Potential Diagnosis Drive is corroding. Below 850 millivolts (Refer to “Drive Corroding”) Saltwater Between 850 - 1100 Drive is protected. Fastener Location lb-in.Increased trim IN range may cause handling problems on some boats which could result in personal injury.

IMPORTANT: On Bravo One, Two and Three Models, the Trim-In Limit Insert, must be properly positioned before installing the trim cylinder anchor pin in the following steps. CAUTION Avoid speedometer hose fitting damage. Disconnect the speedometer hose fitting from the drive shaft housing before removing the sterndrive unit. 3. Cap hoses and plug pump fitting holes. 76631 Sta-Strap Trim Limit Switch Wires Hydraulic Hoses 5. Remove transom locknuts and washers. 73902 Locknuts and Washers (8) 13. Separate the inner transom plate from the gimbal housing assembly. 90-863160 MAY 2000 Page 2A-11. Position the steering lever ground wire as shown or the wire may fatigue and break. 22028 Steering Lever Transom Plate Continuity Wire 1. Install the transom assembly. Tighten locknuts evenly, starting from the center and working outward. Connect gear lube monitor hose. 3. Install water inlet fitting with gasket. Torque bolts and star washers to 45 lb-in. (5 Nm). 76640 Hose To Gear Lube Monitor Hose Clamp. Tighten securely and position as shown. 76656 Water Bypass Fitting 6. Connect water hoses to appropriate fittings. Tighten hose clamps securely. 76641 Seawater Hose To Engine Seawater Pump Seawater Pickup Hose. Torque bolts to 23 lb-ft (31 Nm). 22028 Typical V6 and V8 Gasoline Engines Exhaust Pipe Bolts (4) 76657 71945 Typical Diesel Engine Exhaust Pipe Bolts (4) Page 2A-16. Torque bolts to 23 lb-ft (31 Nm). 76638 Block-Off Plate Bolts IMPORTANT: Make hydraulic hose connections as quick as possible to prevent oil from leaking out of the system. Tighten the two pivot bolts by hand. At the same time, move the steering assembly slightly to ensure proper pin engagement into the pivot bushings. Secure the pin in the clevis with a cotter pin. Spread the cotter pin ends. 71901 Rear Clevis Pin Clevis Cotter Pin Steering Cable End. Route hoses as appropriate to avoid contact with the steering system components.

73860 Models With One Hose Routed Behind Power Steering Control Valve Rear Pressure Hose Front Return Hose 74248. Refer to the appropriate engine service manual. NOTE: If the engine was removed and the shift cable was disconnected, reinstall and adjust the shift cable before proceeding. 2. Ensure that the surface is not damaged. 24725 Drive Shaft Bellows Edge 5. The jaws will open. Lubricate the underside of the lower lip of the shift linkage assembly with Quicksilver Special Lubricant 101. 22025 Shift Linkage Assembly Jaws Open Underside of Lower Lip. Refer to “Special Information” at the front of this section before reinstalling the Trim-In Limit Insert. 11. Ensure that the Trim-In Limit Insert is positioned as shown for the appropriate Bravo model. 75157. Be sure to install the bushings with the small diameter end facing outward. 22029 Anchor Pin Large I.D. Locate the opening in the forward end of the anti-ventilation plate. b. IMPORTANT: Front propeller on Bravo Three sterndrive unit is always LH rotation and rear propeller is always RH rotation. Shift cable end guide must move in direction “A”, when control lever is placed in FORWARD gear position. Hold tool in place over the barrel retainer with a piece of tape. LH ROTATION BRAVO ONE AND TWO MODELS: Forward slot in tool should fit over shift lever stud. If slot does not fit over stud, loosen shift lever stud and slide stud up or down, until slot in tool fits over stud. The cables must have room to move up and down when the control handle is shifted into either forward or reverse. Bravo One U-JOINT IDENTIFICATION RATIO U-JOINT SHAFT MARKING 1.65:1. Do not replace vent screw until reassembly. 76805 Screws Rear Cover Vent Hole 3. If linkage binds; move assembly from side to side while pulling. 76837 Shift Linkage 8. Remove yoke and cam assembly. 76838 Yoke and Cam Assembly 90-863160 MAY 2000.

NOTE: In steps 10 and 12, be sure to note proper order and position of thrust races, thrust bearings and clutch assembly for later reassembly. 76841 Upper Thrust Race Thrust Bearing. Discard cotter pin. 22099 Link Bar Cotter Pin. Apply Loc- tite 271 to outside diameter of seal before installation. Install cotter pin and spread ends. 22099 Link Bar Shift Lever. Remove remaining components. 76861 Standard Bravo Shown Drive Gear and Bearing Assembly Washer CAUTION DO NOT damage spacer when removing first bearing from pinion gear, spacer must be used in reassembly. NOTE: The U-joint seal is located in the seal carrier on standard Bravo drives and in the bearing retainer nut on Bravo X, XZ, XR, and Diesel Bravo. Remove loose bearing. 22180. Wear safety glasses to avoid eye injury. a. Standard Bravo U-Joint:Place U-joint bearing cups in yoke and start them on bear- ing cross members. Install by using adaptor and pressing bearing through yoke and onto cross members. Page 3A-36 90-863160 MAY 2000. Do not over press, as damage to both bearings could occur. Disassembly 1. Remove keepers by pressing down on gear and turning clockwise to release keepers and collar. Be careful not to spin bearings. Inspect gears for pitting, chipped or broken teeth, and excessive or uneven wear. Replace gear if any of these conditions exist. 2. Lubricate parts with gear lube. 76848 Thrust Bearing (Silver Side Toward Garter Spring) Garter Spring 3. Lower clutch over shaft while allowing it to turn clockwise. 22106 Clutch 4. Install keepers. If any of these conditions exist, replace race. 2. Bearing Sleeve Removal (Drive Shaft Housing) 1. Place puller jaws around sleeve. 22219 Drive Shaft Housing Pull Jaws (2 Halves) (91-90244A1) Sleeve 2. Roller Bearing Removal 1. Standard Bravo: To remove roller bearing from drive shaft housing, use a suitable man- drel and drive bearing down into oil cavity. 22260 Bearing And Mandrel. Torque to 175 lb-ft. Secure driver head to puller guide with screw.

Place bearing sleeve against edge of driver head as shown. 22084 Driver Head (91-862530) Puller Guide (91-90774) Screw (91-90775) Bearing Sleeve 2. Secure driver head to puller guide with screw. Lubri- cate inside diameter of roller bearing and place roller bearing on driver head, as shown. 75967 Driver Head (91-862530) Puller Guide (91-90774) The top number designates the thickness of the top thrust bearing race, and the bottom number designates the thickness of the bottom thrust bearing race. Stick thrust bearing to gear. Install clutch assembly. Place thrust bearing on gear. Position cor- rect thrust bearing race on top of thrust bearing. 50304 Thrust Bearing Thrust Race. Apply Special Lubricant 101 to threads of retainer nut and install. Torque retainer nut to 200 lb-ft (271 Nm).Remove tool. 50306 Shift Handle Tool (91-17302) Shifter Shaft 90-863160 MAY 2000 Page 3A-61. Move shifter shaft back and forth as necessary to align lower hole in shift cam assembly with threaded hole in shifter shaft. Apply Loctite 271 to first 2 or 3 threads of screw, install shift cam cap screw and torque to 100-120 lb-in. Apply liberal amount of Spe- cial Lubricant 101 to I.D. of screw recess. 61 1 76852 Screw Recess 90-863160 MAY 2000 Page 3A-63. Apply 3-M Adhesive to O-rings before installa- tion. 50356 Shift Linkage O-ring Water Passage O-ring 22100 50306 Shifter Shaft O-ring Back Cover O-ring 22088 Top Cover O-ring Page 3A-64 90-863160 MAY 2000. Install rear cover and screws. Torque screws to 20 lb-ft (27 Nm). NOTE: To avoid damage to cover, evenly tighten screws until cover is flush against drive shaft housing before torquing screws. Torque nuts and bolt to 35 lb-ft (47 Nm). Torque bolt to 35 lb-ft (47 Nm). 76804 Bolt b. Install rubber plug. 76832 Bolt 4. Fill drive unit with gear lube. (Refer to Section 1B.) Page 3A-68 90-863160 MAY 2000. Hold drive shaft using drive shaft adaptor tool. Retain shims for reassembly. 22262 Clamp Plate O-Ring Spacer Shim(s) Tab Washer 10.

Remove drive shaft and pinion gear. Remove drive shaft bearing cup and shims using slide hammer puller. 22261 Drive Shaft Bearing Cup Shims 90-863160 MAY 2000. Remove water passage O-ring and oil passage quad ring. Replace bearing and bearing cup if cup is pitted, grooved, scored, worn uneven, discolored from overheating or has embedded metal particles. Use Quicksilver Needle Bearing Assembly Lubricant to help keep needles in place. 2. Position bearing assembly over bearing installation tool with number on bearing casing facing up. Press small tapered roller bearing onto drive shaft using universal puller plate. Ensure that smaller outside diameter faces pinion end of shaft. Replace bearing and cup if cup is pitted, grooved, scored, worn, uneven, discolored from overheating or has embedded metal particles. Install outer oil seal with lip facing outward using cup and seal driver. 22459 22087 Oil Seal - Lip Outward Cup And Seal Driver (91-89865) 2. Use either of the following methods: a. LATHE and DIAL INDICATOR METHOD: (1.) Position propeller shaft centers in lathe. (2.) Mount dial indicator at front edge of propeller shaft. Install bearing to shaft using universal puller plate and a suitable mandrel (old bearing race) which supports bearing on inner race. Inspect both the driven gear and the pinion gear for pitting, chipped or broken teeth and excessive or uneven wear. Replace tapered roller bearing and cup if cup is pitted, grooved, scored, worn uneven, discolored from overheating or has metal particles embedded in the cup. Clean opening with a short piece of wire.Ensure that top edge of seal is flush with gear housing surface. Components must be lubricated to obtain accurate bearing preload readings. 2. Install water passage O-ring and oil passage quad ring. Hold in place using 3-M adhesive. Use original shims or if misplaced, start with.050 in. (1.27 mm) thickness. Apply Loctite 271 to threads of screw. 76877 Washer Screw 90-863160 MAY 2000 Page 3B-33.

Install clamp plate on gear housing with nuts (2) and washers (4). Torque to 35 lb-ft (47 Nm). 22262 Clamp Plate (91-43559T) 15. Install the original load ring, thrust ring, O-ring and propeller shaft into the gear housing. Align inner tab of tab washer with V-notch in bearing retainer. 23257 Bearing Carrier Tab Washer Inner Tab Outer Tab 21. Install and tighten bearing carrier retaining nut using retainer wrench until resistance to propeller shaft rotation can be felt (to preload bearings). Ensure that dial rod is aligned with “I” on indicator rod. 22439 Dial Indicator Adaptor (91-83155) Use Quicksilver Special Lubricant 101 on retainer threads; coat outside diameter on carrier mating surfaces with perfect seal. IMPORTANT: The overall preload includes both the drive shaft preload and the gear case preload. Torque fasteners to 35 lb-ft (47 Nm). 76879 Nuts And Washers (3 Each Side) Bolt (Located In Anodic Plate Cavity) 32. Install anodic plate. Torque bolt to 20 lb-ft (27 Nm). Procedures and specifications are identical except for installation of bearing carrier, bearing carrier retainer nut and propeller hub. Position inner tab in V-notch. 77110. Remove nut, washer, spline washer, propeller and thrust hub. 22074 Tab Washer Spline Washer Propeller Thrust Hub 2. Check propeller shaft for side to side movement, as follows: a. Tighten securely. Hold drive shaft using drive shaft adaptor tool. 75921 Drive Shaft Adaptor Tool (91-61077T) Breaker Bar And Socket Pinion Gear Bearing Carrier Retainer 10. Remove clamp plate (installed in Step 2), then remove O-ring, spacer, shim(s) and tab washer. Remove driven gear and bearing. 22283 Driven Gear And Bearing 13. Remove drive shaft bearing cup and shims. Retain shims for reassembly. Remove water passage O-ring and oil passage quad ring. Replace bearing and bearing cup if cup is pitted, grooved, scored, worn uneven, discolored from overheating or has embedded metal particles. Tapered roller bear- ings are damaged when removing.

1. Press tapered roller bearing from shaft using universal puller plate to support bearing on bearing inner race. Use Needle Bearing Assembly Lubricant to help keep needles in place. Position bearing assembly over bearing installation tool with number on bearing casing facing up. Coat casing outside diameter with gear lube. Press small tapered roller bearing onto drive shaft using universal puller plate. Ensure that smaller outside diameter faces pinion end of shaft. NOTE: Needle bearing MUST BE replaced, if removed. Install bearing to shaft using universal puller plate and a suitable mandrel (old bearing race) which supports bearing on inner race. Inspect both the driven gear and the pinion gear for pitting, chipped or broken teeth and excessive or uneven wear. Replace both gears if any of these conditions exist. Place a suitable mandrel (old bearing race) against new bearing race. Place another mandrel on face of gear and press gear and bearing together. Ensure that cup is not canted. Coat cup outside diameter with gear lube. 19917. Replace if necessary. 22085 Speedometer Water Passage Seal Water Passage Seal Replacement 1. Pry rubber seal out with a suitable tool. 22085 Rubber Seal 2. Components must be lubricated to obtain accurate bearing preload readings. 2. Install water passage O-ring and oil passage quad ring. Hold in place using 3-M Adhesive. Use original shims or if lost or misplaced, start with.050 in. (1.27 mm). Apply Loctite 271 to threads of nut. 71543 Washer Pinion Nut 90-863160 MAY 2000. Drive Shaft Adaptor Tool (91-61077T) Breaker Bar And Socket Torque Wrench And Socket Bearing Carrier Retainer Nut 10. Install clamp plate on gear housing with nuts and 4 washers.Install the original load ring, thrust ring and O-ring into the gear housing. Driven gear shimming: a. Reinstall items shown using NEW load ring. IMPORTANT: Always use a new load ring when reassembling.

76884 O-Ring Thrust Ring Load Ring IMPORTANT: Bearing carrier and threads on retainer must be lubricated to prevent corrosion and cracking in gear housing. Install and tighten bearing carrier retainer nut until resistance to propeller shaft rotation can be felt (to preload bearings). Bend remaining tabs down into gear housing. Cushion housing to avoid chipping or scratching paint. Torque fasteners to 35 lb-ft (47 Nm). Nuts And Washers (3 Each Side) Bolt (1) 32. Reinstall drive unit. Refer to SECTION 2A - Removal, Installation and Adjustments. Dial Indicator Set 91-58222A1 Slide Hammer Puller 91-34569A1 Torque Wrench (lb-in.) 91-66274 Clamp Plate 91-43559 Universal Puller Plate 91-37241 Threaded Rod 91-31229 Bearing Driver 91-89867 Bearing Driver 91-89868. Position dial indicator on inner propeller shaft. Position dial indicator on out- er propeller shaft. Rotate outer propeller shaft while observing dial indicator. If de- flection is more than.010 in. (0.254 mm), a bent outer propeller shaft is indicated. Remove the bolt. 76832 Bolt b. Remove the bolt in the anode cavity. 76804 Bolt c. Tighten securely. 72241. Remove clamp plate installed in Step 2, then remove O-ring, spacer, shim(s) and tab washer. NOTE: Be careful not to lose rollers from drive shaft pinion bearing should they drop during drive shaft removal. 72248 Drive Shaft Drive Shaft Pinion Gear 13. Unless you intend to remove the entire pinion bearing, remove needle bearings from pinion bearing race (See pinion bearing removal). Replace bearing and bearing cup if cup is pitted, grooved, scored, worn uneven, discolored from overheating, or has embedded metal particles. Tapered roller bear- ings are damaged when removed. 1. Press tapered roller bearing from shaft using universal puller plate to support bearing. Press large tapered roller bearing onto drive shaft using suitable man- drel or old bearing race on inner race. Ensure larger outer diameter faces pinion end of shaft.

Use Needle Bearing Assembly Lubricant to help keep needles in place. Position bearing assembly over bearing driver with number on bearing casing facing up. Coat casing outer diameter with Quicksilver High Performance Gear Lube. Align punch with opening in snap-ring. Record spline lash reading (for use later in this section). If any of these conditions exist, replace both gear and bearing assemblies and drive shaft pinion gear. Measure shims for reas- sembly reference. NOTE: When pulling bearing cup with puller, shims will be damaged. DO NOT reuse shims. If corrosion is evident, replace bearing carrier. 2. Inspect needle bearing for pitting, grooves, discoloration or embedded particles. If any of these conditions exist, replacement is necessary. Lubricate lips of oil seal and fill area between lips of seal with Quicksilver Special Lubricant 101. Components must be lubricated to obtain accurate bearing preload readings. 2. Install water passage O-ring and oil passage quad ring. Hold in place using 3-M Adhe- sive. Ensure that Loctite does not contact shim mating surfaces. Install thrust cap and appropriate size shim on outer propeller shaft. If shims were lost or ruined where original thickness cannot be determined, install a.050 in. (1.27 mm) shim pack for a starting point. NOTE: Be careful not to lose rollers from drive shaft pinion bearing should they drop during drive shaft installation. 72264 Drive Shaft Drive Shaft Pinion Gear 10. Measure distance between top of gear housing and tab washer using a 0-1 in.Using a dial-type lb-in.Clearance must be.023-.028 in. (0.575-0.700 mm). Take measurement at three locations on pinion gear (120 degrees apart). If shims were lost or ruined where original thickness cannot be determined, install a.050 in. (1.3 mm) shim pack for a starting point. Torque to 200 lb-ft (271 Nm). NOTE: To ensure proper thread engagement, start retainer nut by hand. Turn retainer nut clockwise until thread engagement is felt then turn counterclockwise.

Do not tighten locking bolt at this time. The trim limit switch leads are connected internally to help ensure good electrical integrity. 71415 Trim Limit Switch - Port Trim Position Sender. Ensure that the bell housing flange rests in the second groove from the end of the bellows. Trim Limit Switch Adjustment WARNING When adjusting trim limit switch, use extreme care that engine is not started and. The trim limit point can be determined by measuring the amount of trim cylinder extension.Tolerance ring must be replaced any time gimbal bearing is removed. Inspection 1. Remove sterndrive unit. 2. Refer to Section 2A. 2. Disconnect shift cable from shift plate and remove end guide. 22183 Anchor Screws (2) - Loosen End Guide 3. Remove flanged nut. 4. Shift Cable Installation 1. Insert shift cable end into and through shift cable bellows. 76620 Shift Cable End Shift Cable Bellows. Secure shift cable to bell housing. Hold shift cable retaining nut with wrench and torque flanged nut to 65 lb-in. (7 Nm). 50327 Shift Cable Flanged Nut Shift Cable Retaining Nut. Refer to “Crimp Clamp Tool.” Do NOT allow bellows to flatten. 22117 Crimp Clamp 5. Ensure that core wire is visible in sight port. Tighten anchor screws evenly and torque to 20 lb-in. (2.3 Nm). Refer to Section 2A. 2. Do not use earlier model bellows. WARNING Be sure to follow label directions when using bellows adhesive. 1. Apply bellows adhesive to mounting surfaces on inside of bellows. Allow adhesive to dry until no longer tacky (approximately 10 minutes). CAUTION Support aft end of drive unit when working between bell housing and gimbal hous- ing. CAUTION Exhaust tube clamp may corrode if grounding clip is not installed. 1. Position grounding clip on exhaust tube as shown. 22184 Exhaust Tube Grounding Clip. The hose must be held in place while installing the tapered inserts. Refer to Section 2A. 2.

Remove shift cable from bell housing by loosening anchor screws and disconnecting shift cable end guide from shift bracket. 3. On Standard Transom Assembly - Remove hinge pins from port and starboard sides. 22113 Bell Housing Hinge Pins 13. Suspend cylinders to avoid damage to hoses. NOTE: Pressing is preferred. When using a hammer, install a used hinge pin in the driver to protect the threads. Apply Loctite 271 to outer diameter of seal. 22440 Seal Bearing And Seal Driver. Do not substitute earlier model bellows. 22079 Apply Bellows Adhesive Grounding Clips Part Number WARNING Read and follow package label directions when using bellows adhesive. 5. Torque fitting to 35 lb-in. (4 Nm). 76672 Hex Fitting 7. Install plastic adaptor fitting on speedometer hose. 22461 Hose Plastic Adaptor Fitting Gear Lube Monitor System Components MONITOR TO THROUGH BULKHEAD FITTING HOSE Check hose periodically for condition and replace as necessary. IMPORTANT: Hose and clamps are installed on bell housing hose barb and through bulkhead fitting, before through bulkhead fitting is reinstalled. 76664 Hose - 10 in. Press or tap carefully on seal cup until outer face is flush with casting surface. Do not use sealant. 2. Secure with cotter pin. Spread ends. 22461 22445 Swivel Pin Washer Cotter Pin 4. Clean ground wire ring terminal and screw. 5. Connect ground wire from gimbal housing to gimbal ring. Tighten securely. 22261 Ground Wire Page 4B-40. Lubricate hinge pins with Quicksilver Special Lubricant 101. 71828 Hinge Pin Special Tool (91-63616) 2. Slide hinge pin through gimbal ring and bell housing. Be sure to align screw holes in hinge pin with holes in gimbal ring. Position U-joint bellows on bell housing. Ensure that the bell housing flange (a) rests in the second groove from the end of bellows. Secure shift cable to bell housing. 50327 76673 Shift Cable Retaining Nut. Check that bellows end is not flattened out when crimping in the followIng step. 4. Tighten finger tight. 7.

Tighten jam nut securely. 22183 Threaded Tube Jam Nut. Ensure that bell housing end of core wire is positioned tight against core wire locating tool. Align centerline of template with centerline of dimple or grease fitting (on older mod- els). Vent reservoir pressure by backing out the vent screw two turns after tightening completely. Units without a vent screw have a vented fill cap. Remove the fill neck seal on models without a vent screw. However, if a rebuilt trim cylinder is being installed (which has not been filled with oil), the bleeding procedure should be used to remove the air from the system. The reading should be 2200-2600 psi. (15173-17932 kPa). The pressure should not fall below 1900 psi (13104 kPa). If gauge reading is 1900 psi (13104 kPa) or above, UP pressure test completed. If gauge reading is below 1900 psi (13104 kPa) perform the following: Check for External Oil Leaks, Check for External Oil Leaks,. The reading should be 400-600 psi (2759-4138 kPa). Pressure should not fall below 1900 psi (13104 kPa). Reading below 1900 psi (13105 kPa) indicates a trim cylinder leak. Use the following steps to lo- cate the faulty cylinder. NOTE: If the gauge is connected at the pump, reconnect the gauge at the gimbal housing hydraulic connector. Use the follow- ing test to check for this condition. DO NOT perform this test near flammables or explosives. WARNING Remain clear of the sterndrive unit when performing power trim pump motor tests with pump in the boat and hydraulic hoses connected. DO NOT perform this test near flammables or explosives. 1. Remove the trim pump from the boat. Refer to “Trim Pump Removal.” 2. CAUTION Remain clear of the sterndrive unit when performing power trim pump motor tests with pump in the boat and hydraulic hoses connected. High Ohms Reading (No Continuity)-Replace solenoid. NOTE: See the wiring diagram on page 5A-51.